Brake banjo fitting won't stop leaking

Ok, just replaced calipers and pads on the front of a 1-ton chevy P-van. Now, I'll preface this by saying, "i know what I'm doing." I may have missed something, but lets avoid the responses like, "did you use the little copper washer?"

No matter what I do, it leaks between the banjo fitting and the caliper, and I don't mean just leak, I mean squirt. It looks like I left the bleeder open its so much volume. In fact how I discovered it was when I was bleeding. I wasn't getting any fluid out of the bleeder valve. There was so much leakage at the banjo that no fluid came out the bleeder.

Here's the order of what I did.

1) replaced M/C, rear wheel cylinders, and front calipers/pads.

2) Bled rear brakes

3) moved to passenger side front brake and discovered my little issue. I used new copper washers, and they had seated well enough in the ridges that I had to pick them back out with my fingernail. I cleaned off the surfaces with a blast of brake parts cleaner thinking I had a piece of dirt in there. Still leaks. I went back to the old copper washers. Still leaks. I tried different torques on the banjo bolt. Same leak, no change in volume. I pulled the hose and layed a piece of fine emery on a pane of glass to polish the surfaces of the banjo and look for cracks. Nothing. I annealed one of the copper washers to soften it up. Same leak. Its bad enough that even without any pressure on the pedal, its dripping about once a second

Bad caliper? What gets me is the copper washers have good indentations in them which assumes a good seal to both the caliper and the banjo.

i agree bolt might be making impression in washers but not seeling take washers hose off thread bolt in make sure it treads in far enough to seal look in caliper threads see if old bolt might be broke off in there or if bolt has knicks in the bottom of it from bottoming out

If there is a crack in the caliper, its not visible without the torque of the bolt on it, but I'll take it off and examine further tomorrow. Bolt isn't bottoming. I can thread it in alone the whole way so that the head seats on the caliper. I did that before doing any peripheral work so I didn't get any junk in the caliper.

Thanks for the suggestions. The cracked caliper sounds like the most plausible idea. I'd hate to have to get a new hose, they're not cheap and this one is pretty new.
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All good suggestions. The surfaces of the banjo have been checked for straight and re-trued with emery cloth on a sheet of glass. I agree that the caliper might be off, but since its a rebuild one would assume that a prior owner would have had the same problem (and maybe they did.)

Not metric threads, but good thought.

My buddy was here helping me out yesterday, so he was pushing on the brake pedal as I was helplessly watching all my brake fluid squirt out from between the banjo and the caliper.

I'm going to try a different caliper today and see how that works. If that doesn't do the trick I'll try a new hose. I just hate throwing money at parts to fix a problem. I like to know what's wrong and fix it right http://www.curtisandkim.com/cars.htm

Just cause some cost cutting reman company re-sealed that bugger don't mean it's good. I'd have to say with the copper washers and banjo fitting acting as the known good components that calliper is all that can be wrong.we've all gotten rebuilt or even new bad parts before. esp. from mopar or lucas. I've gotten more brand new pieces of *** than I can count. once I got a caliper for a customers 73 Bavaria took me weeks to find it I put it on went to bleed it and I'll be damned if the threads didn't all come out with the bleeder when I LOOSENED it. thats just one example but it was about a particularly frustrating caliper. I looked all over the country just to get it and the rebuilder that sent it to me didn't even bother using a good core. That without the nationwide search is what I think is happening to you.
I was born to turn the wheel of a stock car.Jake

Well, I finally got the leak to stop, but I don't know why. I deal directly with the reman company and they couldn't figure it out either. I did three different reman calipers and they all leaked, so he rebuilt my core and the leak stopped.

We measured every possible machined surface three times on all of the calipers and they were so identical it was scary, but for some stupid reason only the original would seal. We're all stumped but I don't care... it doesn't leak.

I would have understood a weeping leak, but this was a drip per second if left alone, and a full on squirt if you hit the pedal. There was so much leakage that I never got a drop out of the bleeder when it was open. Scary.

Thanks for all the help. I started losing faith after the third reman caliper, the second hose, the second bolt, and the 8th washer. I had replaced every part at least twice and I couldn't get it to stop.
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